Welding apparatus and method



April 27, 1954 W. N. PLATTE WELDING APPARATUS AND METHOD Filed March 17. 1950 3 Sheets-Sheet l weder flg ff Differeni io1or p fier Tr fgge r Indicator UM OII'CUII IO} U l p Electronic Phase Shift Rm m 01mm Contoctor Heat Comrol Relay FigJ.

Minimum Flashing Voliuge (alb z 4 s Flashing Time- Se l A 1 IO 12 conds INVENTOR WiHiomNPlotte,

' ATTO EY A ril 27, 1954 w. N. PLATTE 2,677,037

WELDING APPARATUS AND METHOD Filed March 1'7, 1950 3 Sheets-Sheet 2 Electronic Phase Shift Special Stepping Upset Contoctor Heot Control pot ntiomet r Reluy COMFO' 1 lo 20 l8 l9 l6 2| Welder Frequency 9 Relay Power Adjustment 353%? g g Reset Source Urm Oscillator 24 26- 25 Li K Upset 29 Valve pp y LEE Source 94 95 Paww 75b u l\ WITNESSES: 5 INVENTOR WilllomN.Plotte.

A ril 27, 1954 w. N. PLATTE 2,677,037

WELDING APPARATUS AND METHOD Filed March 17, 1950 3 Sheets-Sheet 3 m |oo ,noz

Voltage Mul'nspeed Volluqe Shifling Welder Mon" Trigger Controller Circuit Welder 2v Upset q |os 104* Control suppw Uml Fig.6.

INVENTOR d k U. 3J2

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' l I I l 4 /I// i 4se1e9aou l2 ATTORY FloshingTlme-Seconds Patented Apr. 27, 1954 2,677,037 WELDING APPARATUS AND METHOD William N. Platte, McKeesport, Pa., assignor to Westinghouse Electric Corporation, East Pittsburgh, Pa., a corpora tion of Pennsylvania Application March 1'7, 1950, Serial No. 150,293

10 Claims. 1

My invention relates, generally, to welding and it has reference, in particular, to apparatus for and methods of flash welding. Application Serial No. 381,770, filed September 23, 1953 and assigned to Westinghouse Electric Corporation is a division of this application.

Generally stated, it is an object of my invention to provide an improved method of an apparatus for flash welding, which are both inexpensive and reliable and effective in operation. 1

More specifically, it is an object of my invention to provide, in a flash welding system, for progressively varying the relation between the rate of flashing and the flashing voltage.

Another object of my invention is to provide, in a flash welding system, for varying the rela tion between the flashing voltage and the rate of flashing to compensate for increasing temperature conditions during flashing.

Yet another object of my invention is to provide, in a flash welding system, for maintaining the flashing voltage as near as possible to a minimum operating value so as to minimize the formation of craters in the surfaces of the pieces being welded.

It is also an object of my invention to provide, in a flash welding system, for varying the flashing voltage in accordance with the rate of movement of the pieces being welded.

Yet another important object of my invention is to provide, in a flash welding system, for differentiating movement relative to each other of the pieces being welded during the flashing period and using a control voltage having a predetermined relation thereto to control the flashing voltage.

One important object of my invention is to provide, in a flash welding system, for varying the flashing voltage simultaneously with the rate of flashing so as to also maintain the flashing voltage at a predetermined minimum value necessary to maintain satisfactory flashing conditions.

It is also an important object of my invention to provide, in a flash welding system, for using a constant flashing voltage and varying the rate of flashing to maintain a desired predetermined relation between the flashing voltage and the rate of flashing.

A further object of my invention is to provide, in a flash welding system, for utilizing a flashing voltage which is varied while maintaining a substantially constant flashing rate so as to maintain a predetermined relation between the flashing voltage and the rate of flashing.

Other objects will in part be obvious, and will in part be explained hereinafter.

In practicing my invention, in accordance with one of its embodiments, a potentiometer is actuated by the movable platen of flash welding apparatus which may be actuated in any suitable manner to provide a variable flashing rate between members which are to be welded, so as to produce a voltage which changes in accordance with the rate of platen movement. rhis voltage is applied to a C. R. network which differentiates it and produces a control voltage proportional to the rate of movement of the platen. This control voltage is amplified and applied to a valve device in an electronic trigger circuit for operating a stepping relay to both actuate a phase shifting device to vary the flashing voltage, and vary the bias on the valve device so as to eflect cut-off and thus render the trigger circuit periodically effective to actuate the stepping relay to vary the flashing voltage in predetermined relation with movement of the platen.

For a more complete understanding of the nature and scope of my invention, reference may be made to the following detailed description, which may be read in connection with the accompanying drawings, in which:

Figure l is a block diagram of a welding systern embodying the invention in one of its forms;

Fig. 2 is a diagrammatic View of the welding system of Fig. 1;

Fig. 3 shows characteristic curves illustrating the relationship between the minimum value of flashing voltage for effecting satisfactory flashing, and the flashing time;

Fig. 4 is a block diagram of a welding system embodying the invention in another of its forms;

Fig. 5 is a diagrammatic view of the welding system of Fig. 4;

Fig. 6 is a block diagram of a welding system embodying the invention in yet another of its forms,

Fig. '7 is a schematic diagram of the welding system of Fig. 6, and

Fig. 8 shows characteristic curves illustrating the relation between flashing rate and flashing time for the system of Fig. 7.

Referring to Fig. 1, the reference numeral iii may denote, generally, a flash welding machine of a type well known in the art provided with fixed and movable platens. or jaw members. A platen motion indicator ll may be utilized to produce a voltage which varies with movement of the movable platen, and which is applied to a differentiator unit l2, amplified by an amplifier l4, and then applied to a trigger circuit 55 for effecting operation of a stepping relay it. The stepping relay, in turn, may operate a phase shift heat control circuit I 8 for controlling the operation of an electronic contactor 2% to vary the voltage applied to the welder it. An upset control 2| controls the operation of the electronic contactor to terminate the flashing voltage and eiTect rapid movement of the welder platen to produce upset of members being welded.

Referring to Fig. 2, it will be seen that the Welder may comprise a fixed platen 23 for securing one of the members 24 which is to be welded, and a movable platen 25 for securing the other member 26 to be welded. Suitable means may be provided for operating the movable platen 25 such as, for example, a fluid pressure actuating device 28 which may be connected to a source of fluid pressure, represented by the conduit 29, by a flashing valve 30, which may be operable to admit fluid to the device 28 at different rates in different operating positions. An upset valve 32 having an operating winding 33 may be provided for admitting fluid to the device 25 at a relatively high rate in order to effect upset of the members 24 and 25 to terminate a welding operation.

The platen motion indicator H may comprise a resistance device 35 disposed to be connected across a source of voltage such as the batter 35, and having a movable tap 3'! which may be operatively connected to the movable platen 25 so as to provide a control voltage which changes in accordance with the position of the platen. This voltage may be applied to the difierentiator unit I 2, which comprises a C. R. circuit, including a capacitor 39, and a resistor 40, which may be connected to the control grid 420 of a valve device 42. A additional valve device i l may be used in conjunction with the valve device ll? to invert the output voltage thereof for applying it to the amplifier M which may comprise a pair of valve devices 46 and 47!.

The trigger circuit I may comprise a valve device 50 of the gas filled type having its control grid 500 connected to render the device responsive to the cathode voltage of the amplifier I4. The valve device 58 may be utilized to control the energization of the operating winding 52 of the stepping relay it. The stepping relay may be of any suitable type well known in the art comprising, for example, a ratchet mechanism 53 disposed to be actuated by an armature 54 for operating a star wheel 55 connected in circuit relation with the screen grid 50d of the valve device 50 for changing the bias thereon to effect cut-off of the valve device each time it is rendered conductive to step the relay id.

The electronic contactor 20 may comprise a pair of arc discharge devices 59 and 69 connected in the wellknown inverse relation for controlling the flow of current from an alternating current source represented by the conductors 62 to the primary winding 63 of a welding transformer 64 having a secondary winding 55 connected to the platens 23 and 25 for producing a flashing voltage therebetween.

The conductivity of the arc discharge devices 59 and 60 may be controlled in any suitable man ner, such as by means of valve devices ii and 68 having their control electrodes old and E la connected through a control transformer it and a phase shift circuit 72 including the potentiometer device 5'! to the source conductors 62.

In order to provide for maintaining a predetermined relation between the value of the flashing voltage and the flashing rate, the potentiometer 51 may comprise tapered steps which may be calibrated so as to produce a flashing voltage having a relation to the flashing time in accordance with curves such as the curves (1 and b of Fig. 3, which show the relation between the minimum open circuit value of the flashing voltage and the flashing time for producing satisfactory flashing between members of inch and inch bar stock, respectively.

Control of the upset valve 32 may be effected by suitable means such as a limit switch 14, which may be actuated from the movable platen 25 after a predetermined amount of platen movement. Control of the welding current may be eifected by utilizing a control switch lil having an operating winding 76 disposed to be normally energized upon operation of the flash valve 30 which starts the flashing operation. The control switch 75 may be cleenergized through operation of the limit switch 14 so as to terminate the welding current approximately when the upsetting operation takes place.

In operation, the flash valve 30 may be actuated to any desired operating position to admit pressure fluid to the pressure device 28 for actuating the movable platen toward the station ary platen 23 at a desired rate. The control switch 30a is thereby actuated to the closed position, completing an obvious energizing circuit for the operating winding 16 of the switch 15. This applies control voltage through the phase shift circuit 12 to the control electrodes of the valve devices 6'! and 68, so as to render the arc discharge devices 59 and 60 conductive, thereby applying flashing voltage between the members 24 and 26 which are to be welded.

As the platen 25 moves, the movable contact member 37 of the platen motion indicator II moves along the resistance 35, thus varying the voltage applied to the differentiator 12. The changing voltage applied to the C. R. circuit 12 and to the control grid 42c of the valve device t2 produces a cathode voltage across the cathode resistor '18 which is proportional to the rate of change of position of the platen 25. This cathode voltage varies the conductivity of the inverter valve device 44 and applies a corresponding control voltage to the control grid 45c of the valve device 4' of the amplifier M. The cathode voltage or" the valve. device 47 of the amplifier I4 is applied to the control grid 50c of the valve device 5% of the trigger circuit. This renders the valve device conductive, energizing the operating winding 52 of the stepping relay It so as to actuate it one step and change the position of the potentiometer device 57 so as to reduce the flashing voltage.

At the same time, the potentiometer device 56 is actuated one step, thus increasing the negative bias applied to the screen grid sec of the valve device 56. This increase will be sufficient to render the valve device non-conductive As the platen 25 continues to move, the platen motion indicator ll continues to change the voltage applied to the differentiator unit [2, and the valve device 52) of the trigger circuit will, accordingly, be again rendered conductive to step the relay it another step. This operation continues until the limit switch 14 is actuated to interrupt the energizing circuit for the operating winding it of control switch 15, and provide an obvious energizing circuit for the operating winding 33 of the upset valve 32. Flashing voltage is there upon removed from the pieces 24 and 25, and the movable platen 25 is actuated rapidly toward the stationary platen 23 to effect upset of the members which are being welded.

The stepping relay may be reset in any suitable manner, such as by means of a reset push button switch 88, which provides an obvious energizing circuit for the operating winding 52 of the stepping relay.

Referring to Fig. 4, the reference numeral l may again designate, generally, a flash welding machine which may be connected to a source of welding current I3 by means of an electronic contactor 20 whose conductivity may be controlled by a phase shift heat control l8 through a potentiometer 19 under the control of a stepping relay l6 operated from a trigger circuit 15. Operation of the trigger circuit l may be effected by means of an oscillator 82 of the relaxation type, having a frequency control circuit 84. Operation of the trigger circuit to reset the stepping relay may be effected by means of a reset circuit 85. Upset may be effected by controlling the upset control 2| through operation of the stepping relay 16.

Referring to Fig. 5, the reference numeral [0 denotes, generally, the flash welding machine wherein pieces 25 and 26 which are to be flash welded together, are secured in stationary and movable platens 23 and 25, respectively. Operation of the movable platen 25 may be provided for by means of a fluid pressure actuating device 28 which may be connected to a source of pressure fluid 29 through a flashing valve 30 disposed to admit fluid pressure to the device 28 at a predetermined rate. An upset valve 32 having an operating winding 33 may be provided for admitting pressure fluid to the device 28 at a relatively high rate for effecting upset of the members 24 and 25.

The platens 23 and 25 may be connected to a source of alternating current represented by the conductors 62, by means of arc discharge devices 59 and 60 which control the supply of welding current to the primary winding 63 of a welding transformer 64 having a secondary winding 55 connected between the platens. Conductivity of the arc discharge devices 59 and 60 may be controlled by means of valve devices 61 and 68 in a well-known manner, by control voltages derived from a control transformer which may be connected to the source conductors 62 through a phase shift circuit 12 including a potentiometer 51 which may be calibrated in accordance with curves similar to those shown in Fig. 3 for varying the flashing voltage in accordance with the flashing time.

A control switch may be utilized to control the connection of the phase shift circuit 12 to the source conductors 62 for terminating the flow of welding current. Operation of the control switch 15 may be provided for by utilizing a control switch a operatively connected with the flashing valve 30 for commencing a welding operation. A heat cut-off relay 81 having an operating winding 88 connected in parallel circuit relation with the operating winding 33 of the upset valve may be utilized to interrupt the operating circuit of the control switch 15 for terminating the flow of welding current upon upset.

Control of the flashing voltage may be effected by actuating the potentiometer device 51 by means of the stepping relay [6 in a manner similar to that heretofore described in connection with the welding system of Fig. 2. Operation of the stepping relay I6 is controlled by the trigger circuit l5, which may comprise a valve device 90 of the gaseous type for controlling the energization of the operating winding 52 of the stepping relay. Operation of the trigger circuit i5 may be effected by utilizing means such as the relaxation oscillator 92, comprising, for example, a valve device 93 of the gaseous type having adjustable resistance means 94 and 95 in its anode circuit for varying the frequency of oscillation so as to apply periodic voltage pulses to the control grid 900 of the valve device 98 for rendering it conductive.

Reset of the stepping relay 16 may be effected by utilizing a reset push button switch 91 for completing an energizing circuit for the operating winding '52 of the stepping relay independently of the trigger circuit [5. A cut-off relay 98 may be utilized for interrupting the circuit completed by the reset push button switch, so as to effect a stepping action of the relay 16.

In operation, the flash valve 30 may be actuated to apply fluid pressure to the pressure device 28 for actuating the movable platen 25 at a predetermined rate, which has an optimum value on the order of .03 to .04 inch per second for inch and inch flat bar stock. Operation of the flashing valve 30 closed contact member 3M to provide an obvious energizing circuit for the operating winding 15 of the control switch '15. The phase shift circuit 12 is thereby connected to the source conductors 62 through contact member 15a and flashing voltage is applied between the members 24 and 26 which are to be welded.

Operation of the control switch 15 connects the relaxation oscillator 92 to a source of control voltage through contact member 151) so as to periodically render the trigger circuit l5 conductive. The stepping relay IE will, therefore, be periodically actuated so as to change the operating position of the potentiometer device 51 and vary the flashing voltage in predetermined relation with the flashing time.

When the potentiometer device 51 reaches its final operating position, a circuit will be provided through contact member 51h for simultaneously energizing the operating Winding 33 of the upset valve 32 and the operating winding 88 of the heat cut-oif relay 81. Fluid is thereupon applied at a relatively high rate to the fluid pressure device 28 for upsetting the members 2d and 26. Operation of the cut-off relay 81 in-' terrupts the energizing circuit of the operating winding 18 of the control switch 15 and disconnects the phase shift circuit 12 from the source conductors, thus terminating the flow of welding current. At the same time the oscillator 92 is deenergized.

Reset of the stepping relay 16 may be effected by closing the reset push button switch 91, which disconnects the trigger circuit from the source and provides an obvious energizing circuit for the operating winding 52 of the stepping relay. The stepping relay operates, actuating the potentiometer device 51 and completing an obvious energizing circuit for the cut-off switch 58, which interrupts the energizing circuit for the operating winding 52. The stepping relay thereupon returns to the deenergized position as shown and interrupts the energizing circuit of the cut-oif switch, which returns to the deenergized position and again completes an energizing circuit for the stepping relay.

Referring to Fig. 6, reference numeral I may denote, generally, a flash welding machine of a suitable type having a variable or multi-speed motor I00 for varying the rate of platen movement. A voltage controller I 02 may be utilized to regulate the voltage applied to the motor under the control of a voltage shifting trigger circuit I03, which maybe controlled by a timer unit I04. Upset may be effected by means of an upset control 2|, electrical energy being supplied to the welder from a supply source I05.

Referring to Fig. 7, it will be seen that the welder I0 may comprise, as described hereinbefore, stationary and movable platens 23 and 25 for securing work pieces 24 and 26 which are to be flash welded together. Operation of the movable platen 25 may be elfected by means of fluid pressure actuating means 28 which may be sented by the conduit 29 by a an upset valve 32 having an 33 for actuating the valve to sure means 28 directly to the Welding current may be supplied to the Welder I0 from a source I by a welding transformer 64 in a manner well known in the art. Connection of the transformer 64 to the source I05 may be effected by means of a main switch I07 having an operating winding 08. Control of the main switch I01 may be eiiected by utilizing a control relay IIO having an operating winding Ii! disposed to be energized to open the main switch at the time upset is eifected. Operation of the main switch may be effected by means of a start switch H3 which provides an obvious energizing circuit for the operating winding I08.

With the voltage from a source I55 bein substantially constant it has been found desirable to vary the flashing rate between the 24 and 26 to maintain operating winding connect the pressource 29.

time, such as represented by the curves 0 and d in Fig. 8. This result may be attained by operating the flash valve 30 by means such as the multispeed motor I00 which actuates the flash valve to admit pressure fluid at difierent rates, by means of a traveling nut II5.

Operation of the motor I 00 may be efiected by utilizing a potentiometer device 5'2 which may be calibrated to vary the energization of the motor in accordance with the characteristic unit I04, which may include a trigger circuit of the relaxation type. The trigger circuit I5 may comprise a valve device 90 connected in circuit relation with the operating winding 52 of the energize it periodically in accordance with oscilcuit with the valve device 93.

Reset of the stepping relay may be effected by means of a reset push button switch 97 which connects the operating winding 52 for energizing 8 independently of the trigger circuit I5. A cutoff relay 08 may be utilized in connection with push button switch 91 for interrupting the energizing circuit of the operating winding 52 to effect a stepping action.

In operation, the control switch H3 may be actuated to the closed position thus providing an obvious energizing circuit for the operating winding I08 for the main switch I07. The main switch thereupon connects the welding transformer .64 to the source I05. An energizing circuit for the motor I08 will also be provided, extending from conductor H4, conductor II I,

ating the traveling nut H5 at a relatively high speed to open the flash valve 30, and commence the dashing operation. As the traveling nut moves downward, limit switch II 6 closes to set up a reset circuit for the valve operating mechanism.

The stepping relay I6 functions at predetermined intervals of time as determined by the frequency of oscillation of the oscillator 92 to operate the potentiometer device 51 to different positions succession. This progressively changes the speed of the motor I 00 and opens the flash valve 39 at an initially high rate which tapers off so as to increase the flashing rate be tween the members 24 and 26, according, for example, to curve C of Fig. 8.

When the traveling nut actuates the limit switch IIB, control relay H0 will be energized, interrupting the energizing circuit for the operating winding iilll of the main switch. The main switch opens and disconnects the welding transformer from the source. At the same time the operating circuit for the motor I00 is interrupted at contact member I I0b while the oscillator 52 is disconnected from the source at contact member IIL d.

The traveling nut I5 may be reset by operating the switch H3 to reverse position so as to provide an operating circuit for the motor I00 through contact members 3a and 3b and the righthand stationary contacts. When the travupon the equipment is sition ready for the next operation.

From the above description and the accompanying drawings, it will be apparent that I have provided,

the flashing voltage and the rate of flashing in flash Welding. By utilizing the embodiments of my invention, these conditions may be main tained regardless of whether a constant flashing voltage is used, a constant flashing rate or a variable flashing rate. The features of my inabove description and shown in the accompanying drawings shall be considered as illustrative and not in a limiting sense.

I claim as my invention:

1. The method of flash welding which comprises, applying a voltage between members to be welded, moving the members relative to each other to eflect burnofl, and maintaining a predetermined variable relation between the voltage and the rate of relative movement of the members so as to utilize the minimum voltage for maintaining satisfactory flashing between the members.

2. A method of flash welding which comprises, applying a sufficient voltage between members to be welded to effect burnoff of contacting surface portions, moving one member relative to the other, and varying the voltage between the members in predetermined relation to the rate of movement of the moving member.

3. The method of flash welding which comprises the steps, of eflecting relative movement of members to be welded at a predetermined variable rate towards each other, applying a sufflcient voltage between the members to effect burnoii of contacting portions, and varying the voltage inversely relative to the rate of motion to maintain a substantially minimum satisfactory value of flashing voltage.

4. In a control system for a flash welding ma chine having relatively movable jaw members for securing members to be welded, circuit means connected to apply a voltage between the members of suflicient magnitude to produce a burnoff between contacting surfaces, operating means efiective to move the jaw members relative to each other, and control means operable to maintain a predetermined variable relation between the voltage and the rate of movement of the members.

5. The combination with a flash welding machine having relatively movable jaw members for securing members to be flash welded, of circuit means connected to apply a flashing voltage between the members, actuating means operable to effective relative movement of the jaw members, and control means operable to maintain a predetermined variable relation between the flashing voltage and the rate of movement of the jaw members.

6. In a control system for a flash welding machine having movable jaw members disposed to secure members to be flash welded, operating means operable to efiect relative movement of the jaw members, circuit means connecting the jaw members to a source of flashing voltage, and control means including a stepping relay connected to maintain a predetermined variable relation between the flashing voltage and the rate of jaw movement.

7. A control system for flash welding apparatus including relatively movable jaw members disposed to secure members to be flash welded comprising, impulse means operable to produce pulses of electrical energy at predetermined intervals of time, circuit means connecting the jaw members to a source of flashing voltage, and control means including a stepping relay responsive to said pulses connected to maintain a predetermined variable relation between the value of the flashing voltage and the rate of jaw movement.

8. In a control system for flash welding apparatus having relatively movable jaws disposed to grip members to be flash welded together,

circuit means including electric valve means connecting the jaws to an alternating current source of flashing voltage, phase control means actuable to vary the efiective value of the flashing voltage, potentiometer means operable to produce a voltage in accordance with the relative position of the jaws, a capacitor-resistor circuit connected to produce a control voltage proportional to the rate of change of the said voltage, relay means operable to actuate the phase control means, valve means connected to efiect operation of the relay means in response to the control voltage, and control means connected to apply a bias voltage to the valve means in response to operation of the relay means.

9. In a control system for a flash welding machine having a pair of relatively movable jaws movable at variable rates, circuit means including electric valve means disposed to connect the jaws to an alternating current source of flashing voltage, phase control means actuable to control the conductivity of the valve means to vary the flashing voltage in progressively increasing decrements, potentiometer means operable to produce a control voltage in accordance with the relative position of the jaws, relay means operable to actuate the phase control means, an electric valve device connected to effect operation of the relay means in a direction to decrease the flashing voltage, circuit means including a rheostat actuable by the relay means to apply a progressively increasing blocking bias to the valve device to effect periodic operations of the device, and additional circuit means connecting the re lay means to a source of electrical energy to operate the relay means and reset the phase control means and said rheostat.

10. In combination a stepping relay having an actuating coil; an electric discharge device having an anode, a cathode, and a first control electrode, and a second control electrode; means for connecting said anode and cathode in circuit with said coil for actuating said coil when the conductivity of said device is increased; means for impressing and maintaining a first potential of a predetermined magnitude on said first control electrode in any position of said relay to crease and maintain at increased leved the conductivity of said device; and means responsive to the resulting actuation of said relay for inipressing and maintaining a second potential on saaid second control electrode of a predetermined magnitude to revert the conductivity of said device to its initial condition in the actuated position of said relay.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,780,297 Heineman Nov. 4, 1930 1,892,208 Ferris et al Dec. 27, 1932 1,957,759 Coates et a1 May 8, 1934 2,085,583 Hanson June 29, 1937 2,359,324 Manaux Oct. 3, 1944 2,401,780 Undy June 11, 1946 2,404,620 Cooper July 23, 1946 2,443,965 Seeloi June 22, 1948 2,488,899 Cooper et al Nov. 22, 1949 FOREIGN PATENTS Number Country Date 280,659 Great Britain Nov. 24, 1927 507,541 Great Britain June 16, 1939 559,658 Great Britain Feb. 29, 1944 728,374 Germany Nov. 26, 1942 

